Coster BOV

Quality Solutions for Pharmaceutical,Cosmetic & Technical ApplicationsBag

On

Valve

Sys

tem O

verview

BAG IN THE CAN WITHOUT PRODUCT

BAG IN THE CAN FILLED WITH THE PRODUCT

PROPELLANT BETWEEN CAN AND BAG

L

BAG

HØ

ALUMINUM CAN

H

Ø

TIN PLATE CAN

For numerous products packed under pressure, the content

and the propellant must be kept separate. To meet this

requirement, dual compartment packaging was developed.

Coster’s BOV system consists of an aluminum or tinplate

can closed by a valve on which a flexible multilayer film bag,

containing the product to be dispensed, is affixed or welded.

The propellant, liquid gas or compressed gas (nitrogen, air),

is contained inside the can outside the bag and squeezes

the bag to release the product through the valve.

This solution makes it possible to dispense the product

in whatever position the can is held. BOVs are suitable for

cosmetic, pharmaceutical, household and technical prod-

ucts. The multi-layer laminated bag ensures high im per-

meability. The inner layer of polyethylene or poly propylene

is compatible with all the usual aerosol products.

All Coster BOVs guarantee a high drop resistance even

with repeated drops. Valves are available in many different

versions offering varying flow rates suitable for a broad

range of applications. A variety of actuators and caps are

available for sprays, gels and other products.

The system can be used with standard cans, so the same

machines with minor adjustments can be used to fill cans

equipped with either standard or BOV valves.

All materials, including bag and seal, comply with FDA re-

gu lations regarding food contact. Coster maintains a DMF

for its BOVs for pharmaceutical applications.

Coster has established new facilities dedicated to the prod-

uction of BOV valves. The factories are built to the highest

production standards with optimal quality systems.

OVERVIEW

BOV BENEFITS

•OptimisedfOrOxygen-sensitiveprOducts(airless)

•tOtalseparatiOnbarrierbetweenprOductandprOpellant,

hermeticsealwithinthebag:nOcOntaminatiOn,tOtal

prOductintegrityprOtectiOn

•laminatedpOuchOfferssuperiOrbarrier&impermeability

•useOfairasenvirOnmentallyfriendlyprOpellant

•prOductemptyinguptO98%

•hygienicandsterilizable

•canbeusedinanypOsitiOn:360°actuatiOn

•canbeusedwithstandardactuatOrs

•canbeusedwithstandardaerOsOlcans

•canbeusedwithliquidandviscOusprOducts

Coster systems are available in several different versions.

In the NKLCU, KTCS, KTCSU, 20 BOV (press-down) and

NRTLC, NRTLCU (tilt action) ver sions the bag is fixed with

a plug to the valve body. The exclusive, patented valve-

bag coupling and the valve body in acetalic resin give

these versions the high est impermeability, allowing the

use of liquefied pro pellant. Compared to compressed

gas, liquefied pro pel lant has a significant advantage: the

delivery rate is constant, regardless of how much product

has already been dispensed.

These versions can also be pressurized with compressed

gas. Liquefied pro pel lants are filled through the valve. Com-

pressed gasses are filled under-cup. The product is filled

into the bag through the valve’s stem. High impermeabili-

ty makes the system fully suitable for pharmaceutical and

cosmetic ap pli cations.

These ver sions can be used with aluminum and tin plate

cans with max Ø 53 mm and max filling volume 300 ml.

BAG WELDED

In the KWBU (male) and KWBFU (female) versions the film

is welded on the polyethylene or polypropylene valve body.

These versions can be used only with compressed gasses,

with aluminum and tin plate cans with max Ø 66 mm and

max filling volume 500 ml. Also available are special versions

suitable for an irradiation treatment for sterilization.

The bag length L varies from 55 mm to 230 mm,

and it is calculated according to the can utilized.

For standard cans, the approximate bag dimensions are:

tin plate: L = H can - 10 mm; aluminum: L = H can - 15 mm

The bag width varies according to the diameter of the can

utilized: depending on the can size range, the bag width

will be 79, 100 or 120 mm.

No dip tube is needed for bag lengths less than 110 mm.

BAG DIMENSION

BAG FIXED WITH A PLUG

Low, Medium or HighDispensing RatesBag

On

Valve

Fam

ily

NKLCU 20 KNLC 20 KLC

MAIN CHARACTERISTICS AND EXAMPLES OF APPLICATIONS

APPLICATION PROPELLANTVALVE-BAG COUPLING

BOV SERIESCAN

DIAMETERmm

BAG VOLUME

ml

DELIVERY RATE

Food Gels Creams

Compressed Welded KWBU 4180, KWBFU 35 ÷ 66 30 ÷ 500 medium - high

Fixed with plug KTCSU 4180 35 ÷ 53 15 ÷ 250 medium - high

Liquefied Fixed with plug KTCS 4180 35 ÷ 53 15 ÷ 250 medium - high

Post foaming shaving/shower

Compressed Welded KWBU 3100, KWBU 4180, KWBFU 35 ÷ 66 30 ÷ 500 medium - high

Fixed with plug KTCSU 3100, KTCSU 4180 35 ÷ 53 15 ÷ 250 medium - high

Liquefied Fixed with plug KTCS 3100, KTCS 4180 35 ÷ 53 15 ÷ 250 medium - high

Cosmetics Technicals Insecticide

Compressed Welded KWBU 3100, KWBFU 35 ÷ 66 30 ÷ 500 medium - high

Fixed with plug KTCSU 3100, NRTLCU 1190 35 ÷ 53 15 ÷ 250 medium - high

Liquefied Fixed with plug KTCS 3100, NRTLC 1190 35 ÷ 53 15 ÷ 250 medium - high

Pharmaceuticals Nasal Spray

Compressed Welded KWBU 470, KWBFU 35 ÷ 66 30 ÷ 500 low

Fixed with plug NKLCU 450, NRTLCU 1190 35 ÷ 53 15 ÷ 250 low - medium

Liquefied Fixed with plug20KNLC / 20KLC 25 ÷ 40 10 ÷ 75 low - medium

NRTLC 1190 35 ÷ 53 15 ÷ 250 medium - high

Mist water Compressed

Welded KWBU 470 35 ÷ 66 30 ÷ 500 low

Fixed with plug NKLCU 450, NRTLCU 1190 35 ÷ 53 15 ÷ 250 low - medium

Liquefied Fixed with plug KTCS 3100, NRTLC 1190 35 ÷ 53 15 ÷ 250 medium - high

Coster laboratories are at customers’ disposal to define technical details.

BOV FAMILY SERIES : BAG FIXED WITH PLUG

KWBFUcan be irradiated

up to 50 Kgy

KWBU 3100 - 4180 KWBU 470can be irradiated

up to 50 Kgy

KTCS - KTCSU NRTLC - NRTLCUtilt action

BOV FAMILY SERIES : BAG WELDED

1

2

3

4

5

6

7

8

9

10

11

STEM

MOUNTING CUP

EXTERNAL GASKET

INTERNAL GASKET

STEM INSERT

SPRING

HOUSING

BOTTOM GASKET

DISK

BAG INSERT

DIP TUBE

LAMINATED BAG12

LEGENDA

For Sprays, Foams, Gels & LotionsFor Male & Female ValvesBag

On

Valve

Actua

tors

V05.701 V05.2101 V05.2701 (°)SALUS V21.105 TWIST V21.94 CRYSTAL V21.112

ACTUATORS FOR MALE VALVES

FOR FOAMS, CREAMS & LOTIONS

V05.453 V05.496 V05.963 V05.992V05.967 SFERA V31.29 (**)

FOR SPRAY PRODUCTS

ACTUATORS FOR FEMALE VALVES

FOR GELS

NOTE (*) suitable for Ø 49 tin plate and Ø 50 Cebal Transfer Alu cans(**) suitable for Ø 52 tin plate and Ø 53 Cebal Transfer Alu cans (°) suitable for low flow rates

SFERA V31.36 (**)SALUS V21.115

SFERA V31.28 (**)ORBIT V21.97 (*) ORBIT V21.98 (**)

V05.452 V05.981 (°) V05.983V05.982 V05.987

Gassing SolutionsFilling S

tages

& F

illing M

etho

ds

Comprehensive BOV

PRODUCT FILLING METHODS

LIQUEFIED PROPELLANT COMPRESSED GAS

Stage 1: pressurization through the valve with a liquid propellant

Stage 1: under the cup gas filling outside the bag

Stage 2: bag filling with the product through the stem

Stage 2: product filling inside the bag through the stem

FILLING STAGES : UNDERCUP PRESSURIZATION, THROUGH THE VALVE PRODUCT FILLING

FILLING STAGES : THROUGH THE VALVE PRESSURIZATION AND PRODUCT FILLING

3rd STAGE Check of propellant

pressure outside the bag

4th STAGE Release

to remove any residue

from the bag

5th STAGE Filling of product through the valve

inside the bag

2nd STAGE Undercup

pressurization and crimping

of BOV

1st STAGE Insertion of BOV

into the can

6th STAGE Flushing

valve stem

VALVE ACTUATION WITH SUCTION

PRODUCT

AIR – N2

LIQUID PROPELLANT

VALVE ACTUATION WITH SUCTION

PRODUCT

1st STAGE Insertion of BOV

into the can

2nd STAGE Crimping of BOV

3rd STAGE Filling of liquefied

propellant through the valve outside the bag

5th STAGE Release

to remove any residue

from the bag

6th STAGE Filling of product through the valve

inside the bag

7th STAGE Flushing

valve stem

4th STAGE Check of propellant

pressure outside the bag

10.3 mm 8.6 mm 8.6 mm

Laboratory & Production Filling LinesAvailable In a Wide Range of Speeds Filling S

pee

d &

Press

ure

50

40

30

25 50 75 100 125 150 175 200 225 250 275

INJE

CT

ION

PR

ES

SU

RE

IN

BA

RS

PRODUCT FILLING SPEED

KWBU 47020 KNLC 3100

2 KTCS 4180KTCSU 4180KWBU 4180

4KTCS 3100KTCSU 3100KWBU 3100

3 KWBFUNRTLC 1190NRTLCU 1190

NKLCU 45020 KLC 450

1

FILLING MACHINES FOR BAG-ON-VALVES

Coster Tecnologie Speciali, founded

in the early 60’s, serves as a global

partner in the aerosol sector, offering

aero sol components and machines for

filling aerosol, spray and dispensing

prod ucts. Leveraging over 45 years

ex perience and know-how of both its

valve and machinery divisions, Coster

is a world leader in the provision of

innovative services and high quality

products designed to meet customers’

needs. To satisfy the increasing demand

for BOV filling, Coster has developed a

series of machines to allow for the se-

cure processing of dual compartment

systems, ranging from semi-automatic

(for laboratory and small-scale prod-

uction) to fully automatic machines, suit-

able for both liquid and compressed gas

(Nitrogen, Air).

Automatic filling lines for BOVs include:

• Empty cans feeding table

• Automatic BOV valve inserter

• Automatic rotary filling machine

• Automatic system for feeding liquid

product or gel

• Waterbath

• Automatic checkweigher

• Automatic actuator placer

• Automatic cap placer

• Can accumulating table.

Below, automatic filling machine for BOV (up to 60 pcs/min). It performs BOV insertion onto the cans, BOV insertion checking, under the cup pressurisation and BOV crimping, outside the bag propellant pressure checking, filling of product into the bag, BOV stem flushing. Right, close-ups of various machine stations.

The range of Coster BOV filling ma chi-

nes is complemented by a series of an-

cillary machines such as mixing units

for the preparation of post-foaming gel,

which allow Coster to offer complete

support to customers for all BOV filling

requirements.

Coster BOV f i l l ing machines are

cur rently used to fill shaving gels,

pharmaceutical products, cosmetics

and food.

Clockwise from left: BOV insertion and insertion checking; under the cup pressurisation and BOV crimping, propellant pressure checking, release; product filling into the bag; filling head.

recommended filling pressure: 40 bar

do not exceed 50 bar pressure

1 2 3 4

High Drop ResistanceHighly Impermeable System Adv

ance

d Bag

on

Valve

Sys

tems

A selection of products

using Coster BOVs:

left, pharmaceuticals;

above, sunscreens;

right, deodorants

and depilatory creams.

Products using

Coster BOVs:

from left, room fresheners,

fire estinguishers,

insect repellents

and personal defense spray.

Products using

Coster BOVs:

left, food dispensers;

right,

shower and shaving

gels and foams.

BAG LAMINATE MATERIALS AND COMPLIANCE:

Laminates and valve materials comply with FDA food reg-

ulations.

BOV can be gamma-irradiated to max 50 KGy in case of

KWBU 470 series.

- Standard laminate:

LLDPE / Nylon / Aluminum / Polyester

- Laminated material for H202-based products:

LLDPE / Polyester

- Laminated material for sunscreens:

PP / Nylon / Aluminum / Polyester

- Laminated material for post-foaming gels:

LL-MD-LLPE / Aluminum / Nylon

Left, Coster Bag-On-Valves

and Series 1800 actuators

have been selected

by Novartis

for their popular Lamisil

antifungal solution.

POLYESTER 12 µ1

ALUMINUM 9 µ2

NYLON 15 µ3

POLYETHYLENE 76 µ4

Highest level of Automation,Productivity & QualityCoster B

ag O

n Valve

Fac

ilities

Coster Group’s manufacturing facilities are distributed

across a global network. Six plants, including a facility

dedicated to the production of Bag-On-Valves, are located

in Northern Italy, as are the Coster Machinery Division and

an assembly machine plant, ACR. Additional European

plants are located in Holland, Spain and the UK. Other

factories are located in Argentina, India, Malaysia and

the USA. Licensee manufacturers complete the Group’s

production net work; Coster also operates major distrib-

ution centres in Fran ce and Germany.

Coster Group considers the production of Bag-On-Valves

to be a strategic priority. Demand for BOV solutions is

increasing as new applications for the technology are

discovered and implemented. Coster’s vertical production

strategy has led to the construction of a brand new facility

in Cal donazzo, Italy, located next to Coster 3, one of the

largest aerosol valve factories in the world. Coster 4 is

dedicated exclusively to the production of Bag-On-Valves.

The Coster plant near Chicago is dedicated primarily to

the production of Bag-On-Valves for the North American

markets. The main features of the new BOV plants are an

advanced quality system, the capacity to ensure full trace-

ability and a clean production environment.

DEDICATED COSTER BOV MANUFACTURING FACILITIES

Below, high-throughput bag placement machine for BOVs

at Coster 4 facility in Caldonazzo, Italy.

Below, a view of the Coster 3 and Coster 4 plants located

in Caldonazzo, Italy. Coster 3, to the right in the photograph,

is one of the most advanced and highly automated plants

in the aerosol valve sector. Automation is governed by an

integrated, computerized system that continuously monitors

the entire production flow, from the dosage of the raw

materials in the silos to the moulding, collection of moulded

components by laser-guided robots, sorting and finally

packaging and preparation for shipping. Also manufactured

in Coster 3 are the valves used in the Coster 4 facility,

dedicated exclusively to the production of Bag-On-Valves.

Left, Coster USA, Inc., South Elgin, Illinois: the factory

is located near Chicago’s O’Hare Airport. Assembly of

1” valves and bag placement are performed at this facility.